Method of swaging



April 21,1942. c. s. PENFQLD E'rAl. 2,280,352

` METHOD oF swAGING y origina; Filed'Feb, 1, 1940 5 sheets--snaen'l4 14 f Y A l'n Is 11K" 'W6-"5? h ELMER E. JOHNSON 1N VENT ORS` 650.265 H Mmmm 9 9 4 a 15\ P M;

p m' 136 i, 76 12.9 l I gli 68 137 35 f-Zj. a 84 a 41 65 71 39 I3 70 d j 6 3f a3 1 4 f a {I- i 66 i l Y L 6 11 63 50 60 64 @fw a 4o J6 J9 I la A 133 4s 27\ 1.9 3a 134 5, 4547 I" 0 77 I n Y l 4 135,/ /11 44%/ f1" 6` Ef* 74`73 .43 42 4 2 Pi'l 2l 1942. c s. PENFoLD ETAL 2.280.352

METHOD oF `swAGING original Filed Feb. 1, 1940 5 sheets-sheet 2 CHARLES S. PENFLD HMH? L". .1011115011 INVENTOR anzi/6E 1A 13m/swap April 21 19.42. -c. s.`P:-:Nro| n ETAL 2,280,352

METHOD oF lswAGINGf original Filed Feb. 1, 1940 5 sheets-sheet 4 y as Y fi l fag z2.' 89 f y' April 2l, 1942. c. s. PENFOLD ETAL `3?28035Z METHOD oFswAGING v original Filed Feb, 1, 1940 5 sheets-sheet s A Fay. 15. M 95 CHARLES .5. PEA/fom Emme f. JoH/vaoN INVENTORS- .Gfpnaf H. BRALLsFoJeD `the clutch means;

Patented Apr. 21, "1942 Charles rS. Penfold, Elmer E.` Johnson, and George i H; Brailsforironson, Mich., assignors to` H. 1 A. Douglas MfgfCo., Bronson, Mich, a corporation of Michigan i original mentation February 1, 1940, serial No.'

316,720. Divided and this application October i 11, 1941, Serial No. 414,662

s claims. (c1. ca -155.55)

This invention relatesgenerally to a method of swaging and more specifically to va method adapted to swage or crimp a terminalonto a conductor wire. j

The method is particularlydesigned to swage tially on line 9--9 of Figure 3, showing a rear on a terminal `of the so-called snap type,` which is adapted to fit into a receptacle having a fdetent cooperable with a groove or other desirable abutment provided on,` the' terminal, for detachably holding'the terminal lin relation to the receptacle.

This application is adivision of our application, Serial No. 316,720, filed February 1, 1940.

One particular object of the invention is to provide improved method which will simultaneview of the swa'ging mean-s and related structure; Figure l() is a front View in elevation of a part of the apparatus;

Figure llis anenlarged section taken substantially on line I l-I I of Figure 10, showing certain details respecting lthe structure of the jaws and related parts;

Figure 12 is a section takensubstantially on line 'l2- I2 of Figure 11, showing certain details of the cam structure, and the means for mainously swage a terminal onto a conductor wire and onto the insulationin such a manner that' a good electrical and mechanicalfconnection or bond is established between the terminal and conductorwithout the luse of solder or other means.

Many other objects and advantages of the -invention will appear after consideringthe `description hereinafter set forth in conjunction with the drawings annexed hereto.

In the drawings," Figure 1 is'aside View of the swaging apparatus, withportions broken away for illustrative purposes;`

Figure 2 `is `a `top broken aWay;`

planf view, with portions Figure 3 is an enlarged `vertical sectional view taken substantially on line 3-3 of Figure 2,'showing certain mechanisms in inoperative position to receivea terminal as-shown in Figure 1l ,j

Figure `4 is a section substantially correspondz ing toFigure 3, showingl themec'hanisms inFigure 3 in operative` position, in which positionthe swagingjaws are moved centripetally-or` inwardly to swage or crimp a terminal onto a conductor as depicted in Figure 17; I

Figure 5 is `a partial vertical section taken substantiallyon lineS--E of Figure 3, showing a part of the clutch means `employedffor'establishing operative connection between the driving and the driven l,means of ythe apparatus Figure 6 is apartial section taken substantially on lineG-f `of Figure 4, showing other details of Figure 7 is a vertical section taken .substantially` on line 1 -1 of Figure 6, also showing further details of the clutch; Y o

Figure 8 is a section taken substantially on line V3---8 of Figure 4, showing` elements of the machine reciprocated by the driven means; o

Figure 9 is a vertical section taken substantaining the'jaws in normally retracted positions; Figure 13is a partial front view'of the swaging means, with a portion of the structure broken away, so as toiiurther kshow the 'jaws in said retracted position;`

Figure 14 .is a View substantially to `Figure 13, showing thel jaws projected radially inwardly to the fullest extent;` in other words to positions same Wouldtake provided a terminal is not insertedfor swaging;

Figure l5 is a partial sectiontaken substan` tially on line |5^|5 `of` Figure 13, showing details of a j aw and related structure;

Figuresl, 16a,.and 1612` clearly show top, front,

and side views, respectively, actual size, of acertain swaging jaw; o

l Figure 17 is an enlarged sectional view'taken through a part of the swaging means clearly showing the active or operative position ofthe swaging jaws as applied to a terminal for affixing the latter to a conductor;

FigureV 18 is a vertical section taken substantially on line Iii-48 of Figure 17y showing the swaging jaws inythe vactof swaging a reduced portion of a terminal, wire; i

`FigureglQ` is a section taken substantially on line IS--IS vof Figure 17, showing the act of swaging another portion of the terminal onto a wire,

including improved means `for preventing undue distortion of the terminal;

Figure 20 is a section taken substantially on line 26-20 of Figure 17, showingfthe act of swag- 1 ing or crimping an .enlarged portion, such as the skirt,` of a terminal onto vthe insulation of a conductor; Aand Figure 21 isa side view of the terminal shown in Figure 17, after same has been secured to the conductor. o

The apparatus or machine, among other things, preferably includes a swaging'mechanism for attaching a terminal onto a conductor; electricy driving means, means driven thereby including a clutch or coupling: a lost-motion resilient such as the nose onto a connection between the swaging mechanism and the driven means; and means for predetermining the extent or sufficiency of the swaging.

Referring rst to Figures 1 through 4, the parts just referred to, are preferably substantially carried by or mounted upon a heavy metal foundation or mounting plate I as a unit, which may be desirably detachably secured to a suitable support, such as the top of a portable table 2. The table herein shown, is preferably provided with a horizontal shelf 3, from which depends a bracket 4 and a guide member 5. A foot operated treadle 6 is pivotally connected at one end to the lower extremity of bracket 4, and its other end projects through a slot in guide for guidance. As most clearly shown in Figure 1, a rod 1 extends through the shelf, and has one end pivotally secured adjacent the center of the treadle 6, and its other end is connected to a turnbuckle 8. A rod 9 projects through the mounting plate I and the table top, and its extremities are connected to the turnbuckle, and latch or cam lever I Il, respectively. By this arrangement, certain parts are made adjustable, and pressure on the treadle will cause the latch I Il to move downwardly to release the clutch to operate certain mechanisms, which will now be described.

Referring specifically to Figures 2 and 3, the numeral 'I I generally designates driving means in the form of an electric motor, the speed of which is reduced and predetermined, preferably at about 148 R. P. M. The motor is continuously adapted to rotate a drive shaft I2, which, through the 'intermediation of clutching means generally designated I3, is adapted to drive the driven means generally designated I4. The swaging means employed for securing a terminal onto a wire is generally designated I5, and I6 generally designates means providing a lost-motion lresilient connection between the driven means and the swaging means. Thus, downward movement of the treadle will throw in the clutch I3 to cause the drive shaft to rotate the driven means, and the latter to reciprocate the lost-motion means I 6, which in turn operates the swaging means I5. In operation, it is only necessary to thread a terminal on to the` bare end of a conductor wire, insert the terminal into the swaging means I5, and then press down on 'the treadle 6, whereupon the jaws within the swaging means will be moved centripetally to a position substantially corresponding to that shown in Figure 17.

The drive shaft I2' has a driving clutch flange I1 fixed thereto by a spline I 8, secured in place by screws I9. The clutch flange is provided with an annular head having a plurality of radial slots 20, 2|, and 22, clearly shown in Figure '7, which are spaced substantially 120 degrees apart kcircumferentially in non-intersecting relation with respect to its periphery. The entrance side of each slot is preferably chamfered as indicated at 23 so as to pilot or otherwise assist in guiding a reciprocating key member 24, carried by the clutch, into one of the slots. To assist further in this respect, the entering or operating end of the key is chamfered as indicated at 26 in Figure 6.

A clutch or driven shaft 21 is adaptedto be rotated clockwise by the clutch means generally designated I4. A relatively heavy metal bearing member 28, is firmly suitably secured in an upright position tothe'mounting plate I, and provided with a transverse aperture 29 which receives a bushing 30, within which rotates the driven shaft 21. One extremity of the shaft 21 has a cylindrical driven clutch element 3| preferably rmly detachably secured thereto by a pin 32, and the other extremity is provided with a relatively heavy metal annular member 33, which is also preferably firmly detachably secured thereto by a pin 34. As shown, a portion of the bushing is disposed between the bearing member 28, and member 33; in other words the arrangement is such that the bushing provides an abutment for member 33, and the member 28 an abutment for element 3|. The element 3| and annular member 33 are so connected to the shaft 2'I with respect to bearing 2'8, that there is substantially no axial thrust in the aligned connections during the rotation of the shaft.

Considering further, the construction of the clutch means, the driven clutch element 3l is provided with an annular peripheral groove 35, and a radially extending keyway 36. This keyway 36 also extends longitudinally entirely through the member and intersects the clutch shaft aperture 31 and the annular groove 35, but does not intersect the periphery of the member. Reference to Figures 3 and 4, will indicate that the key 24 is adapted to be slid or reciprocated within the keyway 3G to couple and uncouple the clutch, the key cooperating with one of the radial slots 20 through 22 provided in the head of the clutch flange II.

A hole 38 extends longitudinally inwardly from the other or front end of the key 24, and within this hole is a cap 39 backed by a helical spring 40. By this arrangement, the cap 39 is urged forwardly to normally continuously engage the bearing member 28, and urge the key rearwardly. The key, which is provided with a notch 4I, is adapted to be normally held as shown in Figure 3, by means of the latch most clearly shown in Figure 5. The free end of the latch IIJ is continuously held in an elevated position within the annular groove of element 3l. When the element 3| is in the inoperative position shown in Figure 3, the latch II) rests within the notch 4I of the key 24. Thus, assuming the clutch ange I'I is rotating, it will be evident that when the treadle 6 is depressed, the latch I0 will be withdrawn or released from the notch 4I, whereupon the key will be projected by the spring 40 into one of the radial slots 2|] through 22, in which event, the shaft I2 will drive and rotate the clutch shaft 2'1 in a clockwise direction, assuming the machine is viewed from the front. Obviously, the driving and the clutch means could be arranged to rotate the shaft in the opposite direction. A's shown in Figure 3, the clutch is shown in inoperative position, whereas in Figure 4 the clutch is in operative position with the key 24 in engagement with one of the radial slots.

The latch I Il, above referred to, operated by the treadle 6, is shown as having one end pivotally connected to an upstanding bifurcated bracket member 42, which member is preferably anchored to the mounting plate I by screws. The lever and treadle are normally held in the elevated or inoperative full line positions, shown in Figures 1 and 5, by means of a compressed helical spring 43, held in place by a stop pin 44. The stop 44 acts to hold the free end of the latch within the groove 35 of element 3l regardless of whether or not the machine is operating, and also prevents both the latch and treadle from being depressed to an extent farther than is necessary.

The thickness f of "the tlatch `IIJ "is"- substantially uniiorm-throughout'Litsi entirlengthj except-near its `free" end;` which l is'iupturned and more orV less pointedl "Onefside-'lof the'upturned freeend of ther'lvatchfis preferably `provided with a curved o1" slightly convexibevelled portion A"drand a shoulder 46J`v Theslroulderlll most clearly shown in Figure 3 is adapted to provide an abutment, which, when engaged 'by the key 1member 2'4" acts to maintain the driven `element 33, including lthe lost-motion'connection and swaging` means above referred to in predetermined `inoperative posiL tions. T In othrwords; when thetreadle `E. is depressed and quickly released, the latch Y l 0`will release the key into the nearest `revolving radial `slot todrive Athefclutch shaft 21 onecomplete revolution, whereupon,` the key" 24. substantially engages theshoulderf on thelatch to hold the shaft against further rotation. Just prior to the completion of this revolutionary movement, the upturned pointed "end of the latch being pressed upwardly by thespring4 fgradually enters `the notch 4t to gradually withdraw the key Zlifrorn fone of( theradial slots, and when itis actually A withdrawn; throwing out the clutch, the shoulder stop 46, which jin 'the meantime has moved into placeis engaged bythe key. The arrangementissuc'hthata portion of the notchM is at all times presented or open so that the pointed end of the flatchuniayjalways enter the notch as of the opposite sides noi the block: are `preferably provided with 1 vertical Y! groovesv which receive tonguesprovided on'the channels-152;V Obviously, this' tongue'and groove arrangement might be reversed. By this` arrangement theA front si'de of the bloc-k "may slidably"` engage the rear side of the iront plate 5l, andiportions, the: channels 52s`o as to provide a substantial"track:or` guideway for the block; If found desirable, the `front plate, as shown in Figure 10, may be `provided with holes 5`5'adjacent the'lupper extremities of the tongue and groove connections so that the latter may be oiled from thetoutside. ofthe block "54 oppositefthe driven means I3 is provided with a transverse horizontal slot Miv which receives the roller 5l) provided on' `the drive'pin eccentrihcally connected tothe anlao the shaft12`1"nears the vendv of its` revolution.

As clearly shown'inlligure' 6, the side "of the notch `adapted tofengage the bevel 45 isslightly curved orchamfe'red "in order' to permit `the pointed end of thelatch to, better enterfthe notch. Obviously, the driven or lclutchshaft 21 canbe `made toA rotate continuously without `interruption by holding "the treadle down with the foot. `It lwill also be. evident,`that `the revolving: radial slot nearest the key `24, when thelatch is tripped,

will receive the operating end `of the lkey and that since the slotsare spaced `120 degrees apart, the key will engage one of the slots at every third or less lthan everythird of a. revolution of` the i, clutch 'plate "l1, The chamieredportion `2`3` ad Ajacent` each lof4 the radial slots `2l! through ILand `the chamfered portion 26 on th'ekeyl member 24 cooperate in `aimanner whereby to permiteasy entrance ofv the key into either of the slots@ Referring back to the driven means generally designatedA 1.3, theMheavy-annular member 33 secured'tolthe clutch shaftZ'Lis provided with an Aaperture 4T disposed atone side ofthe axis of the member.H A pines is adjustably Aheld in this aperture by a set screw 49. This pin, .clearly shownin Figures 3, 4, and 9', is eccentrically connected tolmernber 33 with its` forward end projecting outwardly `from the member whereby to receive a roller 50. l Thus, the means generally designated IA isadapted tobe driven, `and in turn drives the lost-motion connection-generally `designated |`6,`which willf now be described. t

A relatively `heavy metal upstanding `plate 5l islpreferably iirmly secured to the front end of il( the mounting plate I by screws. The iront plate 5I is also supported and maintained-lin place to some extent by bei-ng secured Yto the swaging means generally designated l5. As clearly shown inliigures 2, 3, 8*, and19, a pair of parallel up@ standing guiding channels 52 .are secured by screws 53 to' the yrear side of the front plate 5l opposite the driven means `Hl. A` substantially rectangularmetal `block 54" is arranged for reciprocating xriovernent-` between the channels. Iwo

nularl memberV 33'." Thus, rotation of `the clutch shaft f2l y'and element" 3 3 will cause' the roller 50 to roll back and 'forth or slide 'within the slot 56 to reciprocatethe blockwith respect'to the channels 52. `lf found; desirabla theblockcould be connected tothe swag-ing means without riding in" guiding channels` Moreover, the driven means could be directlylconnected to the swaging means, withorfwithou'tf a resilient lostemotion connection. Also, aA lost-motion connection, other ,t useito advantage. i i

The block 54 is providedfwithxan upstandins chamber 51," which is open adjacentfits upp'erextremity and internally threaded. An externally threaded; substantially 'cylindricalbushing v58 `is fthr'eadedly connected to the upper extremity of the chamber to close theVsar'ne.` This bushing is provided with a hole5S`J7`vhich` slidably receives a. rod Ell. The lower 'extremity `ofthe roda extends into the `chaniber 51 andlias` a `circular washer' or abutment ailixed theretoA by any ysuit'- ableI meanss such;vr as 'al pinfiSl, interposed between'- the inner orbottoin lend of the bushing 58 and the abutment is an expansible andcontract- "abile helical spring 62 which normally functions to force the abutment including thefrod'downwardly,' into engagementwith the'bottom ofthe chamber 51; when vthe machine Vis in theinoperative position shown` inV Figure V3. The upper `the bushing `58 and is adapted to be` desirably connected to an operating `crank orl arm 65 of `the, swaging means" generally designated l5,

through the intermediation of a coupling element 66. The coupling element 6,6 may "be lsecuredto `the `upper extremity of the rod Gliby'any suitable means, but"as"hereirrshowr'r, zthefbasewof the [coupling is `provided with `an aperture, which re- Ceives the end ofthe-rbd, andthe-latter is secured in place by*A means' otrav pinfclearly shown in Figures 3` and 4; The free endof thearm is preferably tapered andprovidedwithan aperture An angle piece 68 is firmly secured tothe inner orrear side of the ffree end lof' the arm by `anysuitable means, such as rivetsV 69; shown in Figure'Q: .A portion ofthe piece 'isiarran'ged in spacedlapart relation `with respect lto the arm 55 The sidel than one ofr the resilient type could' be t so as to providet a bifurcation adapted to receive the upstanding portion `1li of the element 66. The arm 165 and that portion of the angle piece parallel thereto, and the upstandng portion of the connecting element are eachy provided with an aperture throughwhich extends a pin 1| for pivotally connecting these parts together. As clearly shown in Figure 9 the aperture in the upstanding portion'18 of the element 66, is in the form of a slot 12 within which the pin 1| may ride, so as to allow proper movement of the moving parts without binding. Thus, reciprocating movement of the block 54 will cause movement of the rod 68 and the arm 65, the latter operating the swaging means which will now be described.

The swaging means includes a pedestal 13 having a base portion 14 suitably secured to the mounting plate I by screws 15. The upper extremity of the pedestal 13 is enlarged forming a housing 16, provided with a horizontally arranged transverse opening 11. The upper extremity of the housing 16 is preferably split to provide portions 18 which may be drawn together by a screw 19 to clamp and firmly secure a cylinder 88 within the opening 11. Also assisting to hold the cylinder in place is a key 8| which fits into portions of the cylinder and housing, as clearly shown in Figure 9. The cylinder is provided with a longitudinal aperture 82 which receives a bolt 83, which acts as a. stop to limit the inward movement of a terminal into the swaging means, as shownin Figure 11. The inner end of the bolt may be provided with a small flared hole to act as a pilot for the nose of the l terminal for centering purposes. The bolt 83 is threadedly connected to the cylinder and may be secured ina fixed position by means of a locknut 84.

The cylinder 88 is preferably provided with an 'annular portion 85 which fits into a round aperture 86 provided in the enlarged circular end 81 of the operating arm 65. The front face of the end 81 of the arm is provided with an annular rebate 88, within which is firmly secured a ring or annulus, or more vspecifically a tubular cylindrical cam member 89. This annulus or cam member may be secured in place by any suitable means, but as herein shown, a plurality of pins and screws 98 are used, as clearly shown in Figures 9 and 12. The inner face or periphery of the cam member 89y is provided with a plurality of tangential cam surfaces 9|, preferably six in number, terminating in recesses 92. The outer extremity of the fixed cylinder 88 is also preferably provided with an integral cylindrical head 93 of a diameter greater than the diameter of the portion 85, )and slidably receives a plurality of jaws, the movement of which is caused by the cam' surfaces 9| acting thereupon whenever the operating arm 65 is rotated about the said head of the cylinder. s

Referring now to the improved jaw means and the manner in which same are operatively associated with respect to the head' 93 and vcam member89, the head 'is provided with a'plurality of radially extending grooves 94, which are preferably spaced 60 degrees apart circumferentially and intersect the center and periphery of the head. Each groove is preferably undercut to provide a slot 95, clearly shown in Figure 15, so that each groove and each slot 95 together provide a substantially T-shaped guideway for each yof the jaw members generally designated 96 and |96. As clearly shown in Figures ll, 12, and 15, the head 93 is also provided with aplurality of holes 91 which extend radially inwardly from its periphery. The wall between each hole and slot is provided with a recess 98, clearly shown in Figures 11 and 15. A helical spring 99 is arranged in each of the holes 91. A pin |88' projects transversally from one side of each of the jaws 96 and |96, through the recess 98, and into the hole 91. Each spring is placed under compression or tension and engages a pin |88 to urge the jaws 96 and |96 outwardly to the inoperative position, shown in Figure 11, in which position a terminal to be swaged can be inserted into the opening between them.

The jaw' members 96 and |96 include improved principles of design and construction over existing jaw constructions, and will now vbe described. f

As viewed in Figure 16, each of the jaws 96 is preferably comprised of two complementary parts |8| and |82. The upper and lower surfaces of these parts are substantially flat and parallel. The upper surface of part |8| is provided with the pin |88, above referred to, and its lower surface has a notch |83, which snugly receives a tenon |84, provided adjacent the upper surface of part |82. The parts are preferably held in assembly by a screw |85. Obviously, the notch and tenon arrangement might be reversed, and if found desirable, the parts may be integrally connected together. Part |8| is provided with a portion |86, and integral lateral portions |81 which project outwardly substantially at right angles therefrom. These portions |86 and 81 slidably cooperate with the radial grooves 94 and slots 95, respectively, provided in the head 93 of the fixed cylinder 88, as clearly shown in Figure 15, The side walls adjacent the inner extremity of part |8| converge or taper at substantially 60 degrees as indicated at |88, and its outer extremity is rounded to present a cam surface |89 adapted to cooperate with one of the tangential cam surfaces 9|, provided on the annulus or cam member 89. The outer free end of the taper `is provided with a pair of spaced apart projections or teeth ||8 and the latter of which extends longitudinally a slight distance in advance of tooth ||8. The tooth ||8 is preferably bevelled inwardly to present a substantially triangular swaging face ||2. The tooth presents a substantially rectangular or square swaging face H3. Clearance is provided for the inner end of the stop bolt 83, and the teeth as indicated at I4 and I5, respectively.

The top and side walls of the front extremity of part |82 are also preferably bevelled at 60 degrees to present a substantially rectangular swaging face ||6. Although it is not absolutely essential, it is to be noted that the swaging faces just referred to, are not what you would exactly call pointed, but are preferably formed slightly blunt, as most clearly shown in Figures 18 through 20.

The jaws above described are those designated 96, of which there are three, preferably spaced degrees apart. The jaws generally designated |96 substantially correspond to jaws 96, except for certain details, and are likewise spaced 120 degrees apart, and are arranged between the jaws 96. In other words, all of the jaws are spaced 60 degrees apart, as clearly shown in Figures 12 through 14, and 18 through 20. The only material difference between the jaws is the fact that the jaws |96, are each provided with a proapproximately the same time thatthe swaging teeth are nearing their innermost swaging position. j

Referring specifically to Figures 17 through 21, it will be` apparent that whenV the treadle is tripped to operatethe swaging means, the teeth IIB provided-on the ,sets of jaws 96 and |96 will be forcedradiallyinto the` nose or tapered Vfore end ||8 ofthe terminal ||9` to forge, swage, or otherwise cause,pr eferably rsix, portions |20y of the metalto `flow at af predetermined angle into intimate contact with the conductor wire |2| whereby to provide .an `efficient 'electrical and mechanical connection or bond between the terminal and the wire, the"` latterof which may be of the single or stranded type. Itis to be par-` ticularly noted that when the tapered nose l I8 is properly yswaged, as'shown in Figures 17 and 18, the swage extends substantially the full length of the taper. ThisI offers the distinct advantage of providing a substantially solid `or integral connection between the wire and `terminal adjacent the extreme free endfof the` nose, as clearly shown in Figure 18,whereas farther backthe portions |2||act to squeeze or compress the wire a lesserrextent Inother words, the swaging is more i or less pronounced jat' one point, and gradual or`1tapered`therefrom.` The teeth H6 are preferably cqnstructedto slightly reduce the normal outside diameter of the nose, so that the terniinalfcanf be more easily'inserted into a receptacle. Q y f, e u "e e As `clearly.shown,` thefterminal H9` is also formed to includea cylindricalor land portion |22, through whic'hffthe bare" endA of the wire extends, and.a,largenfcylindrical or skirt portion 23; which receives `a portion of the insulation |24. vThe,terminal maybe provided with a detent.. groove.` or.. abutment,` |25, which l is adapted to cooperate with aldetentrprovided in some desirable form of "a `receptacle.,3 Obviously, the terminal may be otherwis'econstructed, for the one just described is` but'a preferred form.

Thei teeth. provided on the jaws 96 are so arrangedvwith" respect to the teeth H0, that sameuwill, swage the cylindrical or land portion |22 of the lterrnirf1a1,` preferably at three places intermediate the abutment |25, andthe skirt portionLllZS', as' clearlyshown'in Figures 19 and 21. wAll o"f-the jaws are adapted to move centripetally simultaneously, and theblunt 'faces onprojectionslll'l ofthe jaws |56 act to engage, and preferably slightly bite into the periphery or outer wallofvthe terminal, preferably at three placeaintermediate Athe teeth. whereby to prevent the material i at `said intermediate places from becoming distorted. outwardly, while the teeth-I arelswaging the terminal. These projections lll preferablyengage the terminal at or knearthe close ofthe swagingoperation, assist in reshaping or holding the terminal to prevent the'outward flow of the material of which the terminal isy comprised.r Obviously, ifV found desirable theffaces provided on the projections H1 may belmade slightly concave to better confine thegmaterial; Although it is not essential, it has been found advantageous to make the swages causedlby ,teethl |l more effective and positive than those adjacent the nose. In any event, it is preferableto causezmore'metal to Vflow into making fthe conne'ctiony caused by teeth fl l l".

The six teeth ||6 provided on the jaws 96 and |96, as clearly shown in Figures 1`7 and 20,ffunc tion to swagecrimp,or otherwise'forgeportions |26 of the vskirt radially inwardlyl to compress and reduce the cross-sectional size of the insulation |24` and the wire 12|.4 Such reduction locks an uncompressed portion |21 ofthe insulation within the confines of the skirt, and portions of the insulation are forced outwardly into the-six channels Y|28 formed intermediate the swaged portions |26. The crimping of the skirt primarily acts to prevent twisting and bucklingr of the conductor adjacent the skirt, and atthe same time alleviates any strain that might be` placed onthe other Vswaged connections.

As most clearlyshown in Figures 10 and 11, the annulus or cam member 89 projects through andv rotates freely within a hole provided in the front plate 5|.

by-screws |30. `A boss |3| on this 'plate engages the head and maintains'the remainder of the platein `spaced apart `relation to `the jaws and the face of thepart 89 to alleviate friction. This plate |29 is provided with a flared centralhole |32 through which each vterminal isadapted to b-e inserted `to guide the terminal in betweenthe jaws, and engage the stop 83 so as to properly position the portions of the terminal to be swaged with respect to the various swaging teeth.

As .mentioned previously, one object ofthe invention is to provide improved means for swagingra terminal ontoawire. The resilient lost-v motion connection means generally designated i6 is adapted to assist in thisrespect. As clearly shown, when a terminal is being swaged, the block`54` will move downwardly at a" 'faster rate than the `free end ofA th operating arm 25 of the swaging means, andthisis due to the fact that the Yspring 62 within-the block isslightly compressed. In other words, a resilient variable pressure is exerted uponthe swaging jaws ,where` by the` latter may latterly adjust themselves with respect to a terminal. Otherwise expressed, the

, operating arm is operated by resilient means.

This lost-motion connection functions to gradu-v ally ease the Ajaws into a terminal, and primarily prevents the jaws `from movinginwardly beyond the point necessary to provide proper swages. l e Heretofore, the tension placed on thelspring 62 `has Vbeen ascertained by making tests until approximately a forty pound pull is required to remove a swaged terminal from a conductor wire. In other words, if vthe terminal cannot be disconnected from a conductor after a forty pound pull, it is assumed that the terminal has been `properly sw-aged. Thus, it is evident that no accurate or reliable means have been pro'videdfor maintaining the properA tension on the compensating spring 62 after a test has once been made.

vIn order to provide the machine with accurate means for maintaining this predetermined tension, the pin 6| securing the abutment to'the lower end of the rod 60 isV preferably extended througha slot |33 provided in the .block 54 and a slot |34 provided in the front plate 5|; and the pin has a pointer I35.,-as clearly shown in Figures 3, 4, and 10. This pointer is adapted to cooperate with a suitable dial, preferably vprovided on the plate 5|, to indicate the tension in pounds, as illustrated in Figure 10. The upper full line position of the pointer merely indicates that the swagin-g means `is inoperative to receive a terminal, whereas, in the lowerudottedlne position the Apilot plate |29 is preferably detachably secured to the head93 of the cylinderv pointer indicates the fact that approximately 150 pounds tension is required to force the jaws 96 and |96 into a terminal to obtain a proper connection, as shown in Figures 4 and 17. Obviously, a lesser number of swaging jaws may be used, in which less tension will be required.

Accordingly, to maintain the proper tension it is merely necessary to check the clock or register, preferably at regular intervals, and if the pointer fails to register at the 150 mark, showing the .proper tension, the bushing 58 may be adjusted to obtain this tension. Although, from a practical standpoint it is advantageous to check the tension during the swaging operation, it is, nevertheless, feasible to provide an arrangement whereby the desired tension may be ascertained while the machine is in an inoperative or other position. Obviously,- to increase the tension it is only necessary to screw the bushing farther into the block 54. This increased tension may be necessary when, for example, the diameter of a terminal, the thickness of its Wall, or the character of the metal is such that additional tension is required to obtain a proper swaging job. Moreover, if for some reason or other the terminal is of a character that less than 150 pounds tension is required, the bushing 58 may be adjusted to reduce the tension.

To operate the machine, assuming the motor is in operation, it is only necessary to apply force to the treadle 6 to throw in the clutch mechanism generally designated I3 to rotate the shaft 21 and annular member 33, whereupon the block 54 is reciprocated in its guideway by means of the pin 48. The block 54 moves the crank arm B5 to pivot the circular cam member 8S and cause the jaw elements to move centripetally to swage the terminal disposed between the jaws as illustrated in Figure 11.4 One trip of the treadle is sufficient to operate the clutch mechanism and cause the swaging jaws to effect the swaging of one terminal, after which the parts including the shaft 21 are automatically returned to positions whereby they may again be operated by the clutch. As set forth above, certain of the swaging jaws act to prevent distortion of the terminal while it is being swaged onto -a conductor wire. The compensating spring 62, including other parts, provides a lost-motion connection between the crank arm 65 and the block 54 so that a predetermined pressure may be automatically placed upon the terminal while it is being swaged. This compensation has Iproven desirable because in some instances the resistance encountered by the jawsv in swaging the terminal 'and the conductor wire is slightly greater in a given instance than in another, in which event the jaws will simultaneously move together a less distance to compensate for the greater resistance. Thus, the mechanism automatically compensates for slight variation in the bores of terminals or in the diameter of the conductor wires, and as above described, improved means including a scale are provided whereby the amount of pressure may -be denitely ascertained in order that the operator may be in a position to know whether or not the terminals are being properly swaged to' provide a good electrical and mechanical connection.

Although it is not essential, the unit above referred to is preferably covered by a cover or guard |36 whereby to protect an operator from the moving parts. Also, if desired, `an oil tube |31 extending to the exterior of the cover may be provided for the bearing 28.

Having thus described our invention, it is obvious that various modifications may be made in the same without departing from the spirit of the invention; and therefore, we do not wish to be understood as limiting ourselves to the exact form, construction, arrangement, and combination of parts, herein shown and described.

We claim:

l. The method of aixing a metallic sleeve to a metallic conductor means, comprising: disposing the conductor means in position in the sleeve, swaging in the sleeve simultaneously at a plurality of places spaced about the periphery of the sleeve by driving a plurality of pointed jaws into the sleeve at those places, forging localized sections of the sleeve ahead of said jaws producing a force on the underlying metal of said sections causing a flow of the inner metal of the sleeve to forge the sleeve and the conductor means at the plane of said sections into a solid cross-section, and at the same time drive a plurality of projections inwardly to substantially engage portions of the sleeve intermediate said sections whereby to substantially hold or reshape the periphery of said sleeve while said sections are being forged by said jaws.

2. The method of aflixing a metallic sleeve to a metallic conductor means comprising: disposing the conductor means in position in the sleeve, and swaging in the sleeve simultaneously at a plurality of places spaced about the periphery of the sleeve, by driving a plurality of pointed jaws into the sleeve at those places, forging localized sections of the sleeve ahead of said jaws producing a force on the underlying metal of said sections causing a ilow of the inner metal of the sleeve to forge the sleeve and the conductor means at the plane of said sections into a solid cross-section, and at the same time drive a plurality of projections inwardly to substantially engage portions of the sleeve intermediate said sections whereby to maintain said intermediate portions substantially static as respect to any substantial outward flow of the metal while said sections are being forged.

3. The method of ailixing a metal sleeve to metallic conductor means, comprising: disposing the conductor means in position in the sleeve, and swaging in the sleeve simultaneously at at least three places spaced aboutthe periphery of the sleeve by driving at least three jaws into the sleeve at those places, forging localized sections of the sleeve ahead of said jaws producing a force on the underlying metal of said sections causing a flow of the inner metal of the sleeve to forge the sleeve and the conductor means at the Plane of said sections into a solid crosssection, and jaw means acting in conjunction with said jaws operating on said sleeve assisting to prevent outward flow of the metal intermediate said forged sections.

4. The method of afxing a metallic sleeve hav-` ing a nose, land and skirt portion to conductor means, comprising: disposing the conductor means in position in the sleeve, swaging in the sleeve simultaneously on the nose, land and skirt at a plurality of places spaced about the periphery of the sleeve to cause the swaged portions of the sleeve to engage the conductor means in a manner whereby to secure the sleeve to the conductor means, and holding thesleeve to prevent undue distortion thereof -while it is being swaged.

5. 'Ihe method of affixing a metallic sleeve to metallic conductor means, comprising: disposing the conductor means in position in the sleeve,v

swaging in the sleeve simultaneously at a plurality of Vplaces spacedl about the periphery of the sleeve toengage said conductor means by driving a plurality of jaws into the sleeve in those places, and drivinga plurality of projections inwardly'to substantially engage portions of the sleeve intermediate at leastl some of said places whereby to substantially hold or reshape the sleeve while said sleeve is being swaged by said jaws.

6. The method of aflixing a metallic sleeve to a metallic conductor means comprising: disposing the conductor means in position in the sleeve, and swaging inthe sleeve simultaneously at a plurality of places spaced `about the periphery of thesleeve, by driving a plurality of jaws into the sleeve at those places, forging localized sections of the sleeve ahead of said jaws producing a force on the underlying metal of said sections causing a `iiow of the inner metal of the sleeve conductor means having insulation thereon, com-` prising: disposing the conductor means in position in the sleeve with at least a portion of the insulation disposed in said skirt portion, swaging y in the sleeve simultaneously on the land and on the skirt portions at a plurality of places spaced about the periphery of the sleeve by driving a plurality of jaws into the sleeve at those places to cause the swaged portions of the sleeve to engage the conductor means and the insulation in a manner whereby to secure the sleeve to the conductor means and the insulation, and driving aplurality of projections inwardly to substantially engage portions of the sleeve intermediate at least some of the places swaged whereby to substantially hold the sleeve while said sleeve is being swaged by said jaws. f

. 8. The method of alxing a metallic sleeve to metallic conductor means, comprising: disposing the conductor means in the sleeve, moving means in a direction to swage in the sleeve at a` plurality of places spaced about its periphery to engage the conductor means, and substantially at the same time moving other means in the same direction to engage the sleeve intermediate the places swaged whereby to substantially hold the sleeve while it is being swaged.

CHARLES S. PE'NFOLD. `EHJIVIIICE. E. JOHNSON.

GEORGE H, BRAILSFORD. 

